Insulation panel

ABSTRACT

An insulation panel has a top barrier, a bottom barrier, and an insulation core layer disposed between to the top and bottom barriers. The insulation core layer includes a plurality of discrete hydrated compressed puffed polysaccharide particulates that are mechanically and/or chemically adhered to one another and to the top and bottom barriers. The plurality of discrete particulates defines a plurality of voids within the core layer.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a continuation of U.S. patent application Ser. No.15/855,285, filed Dec. 27, 2017, which claims benefit of priority toU.S. Provisional Patent Application Nos. 62/491,651, filed on Apr. 28,2017, and 62/491,666, filed on Apr. 28, 2017, the contents of which arehereby incorporated by reference in their entireties.

FIELD

The presently disclosed subject matter generally relates to insulationpanels and systems and methods for producing and using the same,particularly insulation panels for insulating shipping containers andsystems and methods for producing and using the same.

BACKGROUND

Insulation materials have long been used in a variety of applications,and are being increasingly used in insulated shipping containers toprovide desired or required thermal environments when shipping goods.For example, an insulated shipping container transporting perishablegoods (e.g., refrigerated meals) may increase the longevity of the goodsand, in turn, expand the shipping area of the customer base. While someinsulated shipping containers are designed for long term use, others aredesigned for a more limited lifespan in favor of lower materials andmanufacturing costs. While these limited lifespan shipping containerspractically serve their intended purpose, the ever-increasing volume ofshipping containers results in higher levels of waste, most of which isnon-recyclable at least in part because the insulation materials areoften non-recyclable. Environmentally conscious retailers and consumersare faced with limited environmentally friendly and responsible options,much less cost-effective options, for disposing insulation materials orinsulated shipping containers following use.

Accordingly, there is a need for improved insulation panels forinsulating shipping containers and systems and methods for producing andusing improved insulation panels to address the above-mentionedlimitations. Embodiments of the present disclosure are directed to thisand other considerations.

SUMMARY

Briefly described, embodiments of the presently disclosed subject matterrelate to an insulation panel. Specifically, in one aspect, aninsulation panel may include a top paper-based barrier (e.g., kraftpaper), a bottom paper-based barrier (e.g., kraft paper), and aninsulation core layer disposed between to the top and bottom barriers.The insulation core layer may be mechanically (e.g., by wetting anddrying the paper-based barriers to conform to the contours of theinsulation core layer) and/or chemically (e.g., via a glycosidiclinkage, such as an “O”-glycosidic linkage) adhered to the top andbottom barriers without using adhesives or other tacky materials thatwould compromise the recyclability of the insulation panel. Theinsulation core layer may include a plurality of discrete hydratedcompressed puffed carbohydrate (e.g., polysaccharides such as starch,including vegetable starch, or cellulose) particulates mechanicallyand/or chemically adhered to one another, with the plurality of discreteparticulates defining a plurality of voids within the core layer tocreate a bonded, semi-rigid structure. The hydration may aid themechanical and/or chemical bonds between the particulates.

In some embodiments, one or more of the top and bottom barriers are atleast one of repulpable (e.g., in a paper mill), curbside recyclablewith paper and corrugate materials, supercalendered, andgrease-and-water-resistant. For example, the top and bottom barriers mayboth be repulpable, curbside recyclable, supercalendered, andgrease-and-water-resistant, and one or more of the top and bottombarriers may include kraft paper, machine glazed (MG) paper, smoothfinished (SF) paper, machined finished (MF) paper, glassines,paper-based, and/or supercalendered kraft (SCK) paper.

In another aspect, a method for fabricating an insulation panel mayinclude directing a first fluid (e.g., water or water mixed with acarbohydrate such as starch) onto an upper surface of a bottom barrier(e.g., a paper-based barrier, such as kraft paper) and distributing aplurality of particulates (e.g., discrete compressed puffedcarbohydrate, including starch and cellulose, particulates) about theupper surface of the bottom barrier. The first fluid may hydrate atleast some of the particulates that contact the bottom barrier. Theplurality of particulates may include one or more insulation materials(e.g., carbohydrates, including polysaccharides such as starch,including vegetable starch, or cellulose). The method may also includedirecting a second fluid (e.g., water or water mixed with a carbohydratesuch as starch) onto at least a portion of the plurality of particulates(e.g., between the two or more layers of particulates) to hydrate atleast some of the particulates that contact another layer ofparticulates, and directing a third fluid (e.g., water or water mixedwith a carbohydrate such as starch) onto one or more of at least a lowersurface of a top barrier (e.g., a paper-based barrier, such as kraftpaper) and at least a top surface of the final layer of particulates tohydrate at least some of the particulates that contact the top barrier.Further, the method may include positioning the top barrier on top ofthe plurality of particulates such that the plurality of particulatesforms an insulation section disposed between the top barrier and thebottom barrier. The method may also include compressing the insulationsection (e.g., formed by the plurality of discrete particulates) and thetop and bottom barriers such that at least a portion of the insulationsection mechanically and/or chemically adheres to the top and bottombarriers to form an insulation panel. Depending on the desired size ofthe insulation panel, the method may further include cutting theinsulation panel into a plurality of polygonal sheets. Additionally, themethod may include creasing the insulation panel to facilitateconformation inside of a box such that the creases allow the panel tobend at sharp angles.

In yet another aspect, a system for fabricating an insulation panel mayinclude one or more planar roll dispensers configured to dispense abottom barrier and a top barrier (e.g., paper-based barriers, such askraft paper). The system may also include one or more hoppers (e.g.,vibrating hoppers) positioned above the bottom barrier. The one or morehoppers may be configured to continuously discharge a plurality ofparticulates onto an upper surface of the bottom barrier at a firstdischarge rate. The plurality of particulates may include carbohydrate(e.g., polysaccharides such as starch, including vegetable starch, orcellulose) particulates. The system may further include one or moreconveyors, which may or may not vibrate, configured to distribute theplurality of particulates about the bottom barrier to form one or moreparticulate layers. Further, the system may include one or more fluidvaporizers configured to continuously discharge fluid (e.g., water orwater mixed with a carbohydrate such as starch) onto one or more of theupper surface of the bottom barrier, the plurality of particulates, anda lower surface of the top barrier. The system may also include one ormore compression conveyors comprising one or more conveyor belts and oneor more compression rollers. The one or more conveyor belts may beconfigured to feed the top barrier, the one or more particulate layers,and the bottom barrier to the one or more compression rollers, with theone or more compression rollers being configured to compress the topbarrier, the one or more particulate layers, and the bottom barrier suchthat the plurality of particulates self-adhere (e.g., mechanicallyand/or chemically) and adhere (e.g., mechanically and/or chemically) tothe top and bottom barriers to form an insulation panel. To createsections that are foldable relative to one another, the method may alsoinclude creasing the insulation panel to form two or more sections (oralternatively, three or more sections). In some embodiments, the methodmay also include scoring the insulation panel and/or excessing portionsof the insulation panel to create foldable sections that may beconfigured to form polygonal forms. Each section may be foldablerelative to an adjacent section along the crease or score lines sharedbetween those sections. Depending on the desired size of the insulationpanel, the method may further include cutting the insulation panel intoa plurality of polygonal sheets. The method may also include applying awater-resistant film or disposing a moisture resistant barrier to forman outer layer over the plurality of polygonal sheets.

In a further aspect, a system for fabricating an insulation panel mayinclude one or more planar sheet dispensers configured to dispense abottom barrier and a top barrier (e.g., paper-based barriers, such askraft paper). The system may also include a first fluid vaporizerconfigured to continuously discharge a first fluid (e.g., water or watermixed with a carbohydrate such as starch) onto an upper surface of thebottom barrier. The system may further include one or more hoppers(e.g., vibrating hoppers) positioned above the bottom barrier. The oneor more hoppers may be configured to continuously discharge a pluralityof primary particulates onto the fluidized upper surface of the bottombarrier. The plurality of particulates may include puffed carbohydrate(e.g., polysaccharides such as starch, including vegetable starch, orcellulose) particulates. The system may also include a second fluidvaporizer configured to continuously discharge a second fluid (e.g.,water or water mixed with a carbohydrate such as starch) onto theplurality of particulates. The system may further include one or moreconveyors configured to distribute the plurality of primary particulatesabout the bottom barrier to form one or more particulate layers.Further, the system may include a third fluid vaporizer configured tocontinuously discharge a third fluid (e.g., water or water mixed with acarbohydrate such as starch) onto a lower surface of the top barrier.The system may also include one or more compression conveyors having oneor more conveyor belts and one or more compression rollers. The one ormore conveyor belts may be configured to feed the fluidized top barrier,the one or more particulate layers, and the fluidized bottom barrier tothe one or more compression rollers, with the one or more compressionrollers being configured to compress the fluidized top barrier, the oneor more particulate layers, and the fluidized bottom barrier such thatthe pluralities of the primary and secondary particulates adhere to oneanother and adhere to the top and bottom barriers to form an insulationpanel. Hydration from the first, second, and third fluids may help theparticulates self-adhere and adhere to the top and bottom barriers. Ifthe insulation panel is not already sized as desired, the system mayinclude a cutting assembly having one or more cutting blades configuredto cut the insulation panel according to one or more predetermineddimensions.

The foregoing summarizes several aspects of the presently disclosedsubject matter and is not intended to be reflective of the full scope ofthe presently disclosed subject matter as claimed. Additional featuresand advantages of the presently disclosed subject matter are set forthin the following description, may be apparent from the description, ormay be learned by practicing the presently disclosed subject matter.Moreover, both the foregoing summary and following detailed descriptionare exemplary and explanatory and are intended to provide furtherexplanation of the presently disclosed subject matter as claimed.

BRIEF DESCRIPTION OF THE DRAWINGS

FIGS. 1A-B show a top isometric view of an insulation panel (FIG. 1A)and a creased and folded insulation panel (FIG. 1B), while FIG. 1C showsa top isometric view of two creased and folded insulation panels, inaccordance with an exemplary embodiment;

FIG. 2A shows an exploded view of an insulation panel, in accordancewith the exemplary embodiment shown in FIGS. 1A-C, while FIGS. 2B-C showexploded views of an insulation panel formed without top and bottombarriers and having a single foamed particular layer (FIG. 2B) andmultiple foamed particulate layers separated by a divider (FIG. 2C) inaccordance with other exemplary embodiments;

FIG. 3 shows a side view of a panel manufacturing system, in accordancewith an exemplary embodiment;

FIG. 4 shows a side view of a panel manufacturing system in operation,in accordance with an exemplary embodiment;

FIG. 5 shows a perspective side view of a feeder subsystem of a panelmanufacturing system, in accordance with an exemplary embodiment;

FIGS. 6A-B show a side view (FIG. 6A) and a perspective side view (FIG.6B) of a compression subsystem of a panel manufacturing system, inaccordance with an exemplary embodiment;

FIG. 7A shows a perspective side view of creasing and cutting subsystemsof a panel manufacturing system, in accordance with an exemplaryembodiment, while FIG. 7B shows a perspective side view of creasing andcutting subsystems of a panel manufacturing system, in accordance withanother exemplary embodiment;

FIGS. 8A-E show a panel manufacturing system having a bulk particulatefeeding system, according to an exemplary embodiment. Specifically, FIG.8A is a front isometric view, FIG. 8B is a right side perspective view,and FIG. 8C is a rear isometric view of the panel manufacturing systemhaving a bulk particulate feeding system, in accordance with anexemplary embodiment. FIG. 8D is a zoomed in perspective side view of afeeder subsystem and FIG. 8E is a zoomed in perspective side view ofcreasing and cutting subsystems of the panel manufacturing system, inaccordance with the exemplary embodiment shown in FIGS. 8A-C;

FIG. 9 shows a panel manufacturing system having a controller, inaccordance with an exemplary embodiment; and

FIG. 10 is a flowchart of a method for fabricating an insulation panel,in accordance with an exemplary embodiment.

DETAILED DESCRIPTION

To facilitate an understanding of the principals and features of thedisclosed technology, illustrative embodiments are explained below. Thecomponents described hereinafter as making up various elements of thedisclosed technology are intended to be illustrative and notrestrictive.

Embodiments of the disclosed technology include an insulation panelhaving top and bottom paper-based (e.g., kraft paper, which may betreated or modified to assist in protecting the insulation core layerfrom moisture) or plastic-based barriers with an insulation core layerhaving puffed carbohydrate (e.g., polysaccharides such as starch,including vegetable starch, or cellulose) particulates disposed betweento the barriers. After the barriers and the particulates are sprayedwith fluid (e.g., water or water mixed with a carbohydrate such asstarch) during manufacturing, the particulates of the insulation corelayer may at least partially directly adhere to one another and to thetop and bottom barriers via one or more of mechanical adhesion (e.g., bywetting and drying the barriers to conform to contours of theparticulates) and chemical adhesion (e.g., covalent bonds, ionic bonds,hydrogen bonds, or any combination thereof. The particulates of theinsulation core layer may at least partially directly adhere to oneanother and/or to the top and/or bottom barriers via direct chemicaladhesion or adhesive layer (which may work in cooperation withmechanical adhesion). The particulates and/or the top and bottombarriers may be hydrated to facilitate the direct mechanical and/orchemical adhesion. The direct chemical adhesion can be via a covalentbond, including, but not limited to, a glycosidic linkage (also referredto interchangeably as a glycosidic bond). A glycosidic bond or linkageis a bond between the hemiacetal or hemiketal group of a sugar orsaccharide molecule (e.g., monosaccharide, disaccarid, oligosaccharide,polysaccharide, and the like) to an —OR group, such as a hydroxyl group.A glycosidic bond can also be a bond between the hemiacetal or hemiketalgroup of a sugar or saccharide and another atom, such as a carbon,nitrogen, sulfur, selenium, and the like. Such bonds may also bereferred to as C-glycosides or C-glycosyl compounds (carbon),N-glycosides or glycosylamines (nitrogen), S-glycosides orthioglycosides (sulfur), and selenglycosides (selenium). In anembodiment, the particulates of the insulation core may at leastpartially adhere to one another and to the top and bottom barriers via aglycosidic linkage. That is, at least a portion of the top surface ofthe insulation core layer may at least partially adhere to the topbarrier and at least a portion of the bottom surface of the insulationcore layer may at least partially adhere to the bottom barrier. Althoughthe exemplary embodiments discussed herein refer to glycosidic linkagesor bonds, any types of chemical or chemical adhesive bonds (e.g., ionicbonds) are contemplated as well. After being sprayed with fluid andpositioned relative to one another, the barriers surrounding theinsulation core layer may be compressed in a compression conveyor tofully adhere the particulates to one another and to the top and bottombarriers to form an insulation panel. After compression, the insulationpanel may be creased (longitudinally with the feed direction orlaterally perpendicular to the feed section) and cut (longitudinallywith the feed direction or laterally perpendicular to the feed section)to a predetermined size.

A discharge assembly may discharge a continuous flow of particulatesonto the bottom barrier (or directly onto a conveyor in embodiments withno bottom barrier), while a roller assembly unrolls the top and bottombarriers at the appropriate position. Depending on the volume of thedischarge assembly and the output capacity of the particulate source(e.g., an extruder), an additional feed system may be used to maintainsupply levels. Also helping maintain supply levels, a reclamation systemmay collect scrap materials from various other systems in themanufacturing process, grind and shred the scrap materials to apredetermined maximum size and shape, and direct the shredded scrapmaterials back into the feed system.

In another embodiment, the insulation panel includes an insulation corelayer having puffed carbohydrate (e.g., polysaccharides such as starch,including vegetable starch, or cellulose) particulates without top andbottom barriers. Optionally, the insulation core layer may includemultiple porous layers of puffed carbohydrate particulates that are atleast partially adhered directly to one another or separated by one ormore dividers (e.g., a plastic sheet), which may be non-porous such thatthe dividers do not allow moisture to pass through. In some embodiments,the insulation core layer may include multiple porous layers of puffedcarbohydrate particulates that are at least partially adhered directlyto one another or separated by one or more paper-based barrier dividers(e.g., kraft paper, or treated kraft paper) or one or more plasticbarrier dividers. The insulation core layer may be shrink-wrapped orotherwise sealed or treated for moisture resistance in lieu of or inaddition to moisture resistance provided by the top and bottom barriers.

After the particulates are sprayed with fluid (e.g., water or watermixed with a carbohydrate such as starch) during manufacturing, theparticulates may at least partially adhere to one another via mechanicaladhesion (e.g., wetting and drying the paper barriers to conform to thecontours of the particulates) and/or chemical adhesion (e.g., covalentbonds, ionic bonds, hydrogen bonds, or any combination thereof), and themechanical and chemical adhesion may work in cooperation. Theparticulates (or layers thereof) may at least partially adhere to oneanother and/or to one or more dividers via direct mechanical and/orchemical adhesion or, in other embodiments, via one or more adhesivelayers. The direct chemical adhesion can be via a covalent bond,including, but not limited to, a glycosidic linkage (also referred tointerchangeably as a glycosidic bond). A glycosidic bond or linkage is abond between the hemiacetal or hemiketal group of a sugar or saccharidemolecule (e.g., monosaccharide, disaccarid, oligosaccharide,polysaccharide, and the like) to an —OR group, such as a hydroxyl group.A glycosidic bond can also be a bond between the hemiacetal or hemiketalgroup of a sugar or saccharide and another atom, such as a carbon,nitrogen, sulfur, selenium, and the like. Such bonds may also bereferred to as C-glycosides or C-glycosyl compounds (carbon),N-glycosides or glycosylamines (nitrogen), S-glycosides orthioglycosides (sulfur), and selenglycosides (selenium). In anembodiment, the particulates of the insulation core may at leastpartially adhere to one another and/or to one or more dividers via aglycosidic linkage. That is, at least a portion of the bottom surface ofa top layer of particulates may at least partially adhere to the topsurface of a bottom layer of particulates and/or the top surface of adivider and, similarly, the top surface of a bottom or lower layer ofparticulates may at least partially adhere to the top layer and/or adivider. Although the exemplary embodiments discussed herein refer toglycosidic linkages or bonds, any types of chemical or chemical adhesivebonds are contemplated as well. After being sprayed with fluid andpositioned relative to one another, the insulation core layer may becompressed in a compression conveyor to fully adhere the particulates toone another to form an insulation panel. After compression, theinsulation panel may be creased (longitudinally with the feed directionor laterally perpendicular to the feed section) and cut (longitudinallywith the feed direction or laterally perpendicular to the feed section)to a predetermined size. Additionally, the insulation panel may beshrink-wrapped or otherwise sealed or treated for moisture resistance.The one or more dividers may help layers of particulates adhere to oneanother, and provide structural support or moisture resistance to atleast a portion of the insulation panel. By including multiple layers ofparticulates, which can have different sizes, shapes, densities, andmaterials, allow for the insulation panel to be customized for aparticular application.

The resulting insulation panels of the embodiments described herein haveparticular applicability in shipping containers, such as the expandableshipping container disclosed in the U.S. Provisional Patent ApplicationNo. 62/491,651 filed Apr. 28, 2017, the subject matter of which isincorporated herein by reference. For example, embodiments of theinsulation panel disclosed herein may be used to form one or more panelsand/or flaps within a shipping container. One exemplary advantage ofusing exemplary embodiments of the disclosed insulation panels is thatthey can be one or more of (or all of) repulpable, curbside recyclable,grease-and-water-resistant, and moisture-resistant because one or moreof (or all of) its top and bottom barriers and foamed particulate layercan have those characteristics. In some embodiments, the insulationpanel is also compostable and biodegradable.

Referring now to the figures, in which like reference numerals representlike parts, various embodiments of the disclosure will be disclosed indetail.

In some embodiments, as shown in FIGS. 1A-C and FIG. 2A, an insulationpanel 10 may have a top barrier 20 and a bottom barrier 30 adjacent thetop and bottom surfaces, respectively, of a foamed particulate layer 40.In other embodiments, insulation panel 10 may have foamed particulatelayer 40 without top barrier 20 and/or bottom barrier 30 (as shown inFIG. 2B) or multiple foamed particulate layers 40 separated by one ormore dividers 50 (as shown in FIG. 2C), though it is contemplated thatmultiple foamed particulate layers 40 may be stacked without dividers.Foamed particulate layer 40 may be formed from discrete expandedparticulates of any type, including, for example, foamed or puffeddiscrete particulates. For exemplary purposes herein, particulate layer40 is discussed as a foamed particulate layer. Top barrier 20 and bottombarrier 30 may be thin, paper-based barriers, such as kraft paper,machine glazed (MG) paper, smooth finished (SF) paper, machined finished(MF) paper, glassines, and/or supercalendered kraft (SCK) paper. In someembodiments, the paper weight of top barrier 20 and bottom barrier 30ranges from 10# to 70#, and from 20# to 60# in other embodiments, andfrom 15# to 30# in further embodiments, though other weight ranges arecontemplated. Top barrier 20 and bottom barrier 30 may be one or more ofrepulpable, curbside recyclable, supercalendered,grease-and-water-resistant, kraft paper, machine glazed (MG) paper,smooth finished (SF) paper, machined finished (MF) paper, glassines,and/or supercalendered kraft (SCK) paper. Top barrier 20 and/or bottombarrier 30 may optionally include a laminant or coating to improvewater-resistance. In some embodiments, to meet the OCC-E protocoldeveloped by the Fiber Box Association, a laminant or coating includedon top barrier 20 and/or bottom barrier 30 is repulpable and curbsiderecyclable. Foamed particulate layer 40 at least partially chemicallyadheres directly to top barrier 20 and bottom barrier 30 via a covalentbond, including, but not limited to, a glycosidic linkage. Bookending atleast top and bottom surfaces of foamed particulate layer 40 between topbarrier 20 and bottom barrier 30 can provide several advantages overfoamed particulate layer 40 alone, including providing a printablesurface, a barrier to airflow and thermal transfer, and a barrier tomoisture and liquid intrusion (thereby also preventing damage to foamedparticulate layer 40).

Insulation panel 10 shown in FIG. 1A, and similarly the embodiments ofinsulation panel 10 shown in FIGS. 2B-C, may be creased (e.g., by acreasing assembly) such that insulation panel 10 has multiple sections(e.g., three or more) separated by creases (e.g., two or more), as shownin FIG. 1B. The sections are foldable relative to one another along thecreases, with the extent of rotation being based upon the depth andangle of the creases. In some embodiments, as shown in FIG. 1C, thesections are foldable relative to one another along creases up to about90°. In this fashion, two insulation panels 10 may be oriented relativeto one another as shown in FIG. 1C to cover six sides of a rectangularor cubic box for placement within an expandable container (e.g., theexpandable shipping container disclosed in the U.S. Provisional PatentApplication 62/491,651). Insulation panel 10, with or without top andbottom barriers 20, 30, may be sized (e.g., formed, cut and creased) tofit within an expandable container or other application. For example, insome embodiments, insulation panel 10 has a minimum length of about 4″,a minimum width of about 4″, and a minimum thickness of about 0.1″.).

As shown more clearly in FIGS. 2A-C, foamed particulate layer 40 is madefrom a plurality of foamed particulates 42, such as, for example,discrete compressed puffed carbohydrate (e.g., polysaccharides such asstarch, including vegetable starch, or cellulose) particulates. Whilereferred to herein as discrete foamed particulates 42, any type ofexpanded or puffed particulate is contemplated for purposes herein.Foamed particulates 42 used in foamed particle layer vary in diameterbetween about 0.125″ and 6.0″ in some embodiments, and between about0.5″ and 2.0″ in other embodiments. One or more of the plurality ofvoids between the foamed particulates 42 that make up particulate layer40 may be partially filled with one or more of a cellulose filler and ashredded paper filler. In some embodiments, foamed particulates 42include at least about 20% by dry-basis weight starch polysaccharidesand the remainder is formed from a mixture of one or more of non-starchpolysaccharides, water, colorants, additives, rheology agents, additivesof lignocellulosic origin, adhesives, plasticizers, hydrophobic agents,nucleating agents, and other inert fillers. In other embodiments, foamedparticulates 42 include less than about 90% starch (e.g., vegetablestarch), as limiting the weight percentage of starch under 90% helpsenable insulation panel 10 to bend without snapping or breaking, therebyassisting with resiliency. In further embodiments, foamed particulates42 include no more than about 85% starch (e.g., vegetable starch) tofurther increase the resiliency of the foamed particulates 42. Theirregular shape of the discrete particulates may provide thermalprotection in the event that insulation panel 10 breaks because theuneven surface of the irregularly shaped particulates formed by themating contact surfaces on each side of the break would impede thermaltransfer more effectively than flat contact surfaces of a “clean” break.

In some embodiments, foamed particulates 42 used in foamed particlelayer 40 vary in diameter of their longest cross-section between about0.125″ and about 6.0″. In other embodiments, the shortestcross-sectional dimension of each of foamed particulates 42 is less thanabout 6.0″ prior to forming foamed particulate layer 40. Using discretefoamed particulates 42 also advantageously allows for an integral foamedparticle layer 40 (e.g., not formed by adhering multiple layers togetherand trimming to a desired size/shape) having any desired shape and sizeregardless of dimensions selected during extrusion and without any wastematerial from having to trim insulation panel 10 to the desired shape orsize. In some embodiments, foamed particulates 42 used in foamedparticulate layer 40 may be substantially uniform in one or more of sizeand shape, and may be substantially uniform or vary in size and shapeacross multiple foamed particulate layers 40. Foamed particulates 42 mayhave particle densities varying from about 0.2 to about 2.0 pounds percubic foot, more particularly about 0.4 to about 0.9 pounds per cubicfoot in some embodiments, before forming foamed particulate layer 40,and may be substantially uniform or vary in density across multiplefoamed particulate layers 40.

To form foamed particulate layer 40, foamed particulates 42 may at leastpartially adhere to one another and collectively define a plurality ofvoids to create a bonded, semi-rigid structure of foamed particulatelayer 40. For example, the foamed particulates 42 may at least partiallyadhere to one another by application of adhesive formulations or bypolymerization reactions between the polysaccharide components withinfoamed particulates 42 forming linkages between foamed particulates 42.By using a plurality of discrete foamed particulates 42, the density ofinsulation panel 10 (density of particulates 42 multiplied by thepercentage of non-void space making up insulation panel 10) can becustomized as desired, and may be lower than the density of a solidsheet of starch foam. This lower density can provide several advantages,including using less material without sacrificing thermal performancebecause panel thickness, the controlling factor in thermal performance,remains the same. Additionally, by using less material, insulation panel10 also weighs less than designs requiring a higher density, animportant consideration for shipping containers. In exemplaryembodiments, insulation panel 10 may have a density from about 0.025 toabout 40.0 pounds per cubic foot (calculated using the imageJ testthrough a front-to-back cross-section extending through top and/orbottom barriers), more particularly about 0.01 to 2.0 pounds per cubicfoot and a thickness between about 0.001 to about 10 inches, moreparticularly about 0.25 to about 2.0 inches. Insulation panel 10 may beformed with between about 20% to 80% voids, more particularly about 30%to 60% voids.

In additional to decreasing density of insulation panel 10, a highervoid percentage also provides increased space for filler materials(e.g., cellulose filler, which may be wetted, recycled trim materialfrom manufacturing insulation panel 10). The plurality of voids definedby foamed particulates 42 may be filled with a solid or fluid oralternatively left empty (e.g., filled with ambient air). For example,one or more of the plurality of voids between the foamed particulates 42that make up foamed particulate layer 40 may be partially filled withone or more of a cellulose filler and a shredded paper filler.Alternatively, one or more of the plurality of voids may be at leastpartially filled with one or more of materials of lignocellulosicorigin, moisture scavenging agents, odor absorbing agents, phase-changeagents, and other inert fillers.

When insulation panel 10 includes multiple foamed particulate layers 40,as shown in FIG. 2C, foamed particulates 42 in each layer 40 may atleast partially adhere to particulates 42 of another layer 40 and/or toupper and lower surfaces of divider 50, respectively. Divider 50 may bea non-porous material (e.g., a plastic sheet), and may be properties asdesired based on the final application of insulation panel 10. Forexample, divider 50 may structurally support foamed particulate layers40, provide moisture protection or thermal conductivity resistancebetween foamed particulate layers 40, or separate different foamedparticulate layers 40 during manufacturing. In some embodiments, divider50 may be a paper-based barrier as described herein.

In some embodiments, insulation panel 10 may be at least partiallyshrink-wrapped or otherwise sealed by a protective outer barrier (notshown). For example, the semi-rigid structure of foamed particulatelayer(s) 40 may be at least partially adhered to the outer barrier viaapplication of adhesive formulations or by direct mechanical fusion tothe surfaces of the material layers or by chemically and/or mechanicallyadhering the outer barrier to the material layer. The outer seal mayinclude one or more layers of porous and/or non-porous materials and maybe bonded to and/or imbedded within the semi-rigid structure of foamedparticulate layer(s) 10. For example, in some embodiments, the outerseal may consist of lignocellulosic materials such as but not limited touncoated paper, clay or chemically coated one- and two-sided paper,polymer-coated or laminated one- and two-sided paper, uncoatedcorrugated substrates of one or more layers, wax or chemically coatedcorrugated substrates of one or more layers, and polymer-coatedcorrugated substrates of one or more layers. In other embodiments, theouter seal may consist of polymeric materials including but not limitedto films, mesh screens, non-woven substrates, and rigid polymericstructures. In further embodiments, the outer seal may consist of metalsurfaces including but not limited to metal foils, mesh screens, solidmetal sheets, and polymers with metalized surfaces.

Similarly, in some embodiments, insulation panel 10 may be at leastpartially enveloped in a protective sheath (not shown), which mayinclude porous or non-porous materials (e.g., plastic, kraft paper,treated materials for moisture resistance, etc.) and provide structuralsupport to insulation panel 10. The sheath may envelope insulation panel10 in cooperation with the outer seal. Unlike the outer seal, however,it is contemplated that the sheath is not adhered to the semi-rigidstructure of foamed particulate layer(s) 40 in some embodiments. Inother embodiments, the sheath may be at least partially adhered directlyto insulation panel 10 or to the outer seal via application of adhesiveformulations or by direct mechanical fusion to the metal surfaces of thematerial layers of the outer seal or by chemically and/or mechanicallyadhering the outer barrier to the material layer. In some embodiments,the sheath may consist of lignocellulosic materials such as but notlimited to uncoated paper, clay or chemically coated one- and two-sidedpaper, polymer-coated or laminated one- and two-sided paper, uncoatedcorrugated substrates of one or more layers, wax or chemically coatedcorrugated substrates of one or more layers, and polymer-coatedcorrugated substrates of one or more layers. In other embodiments, thesheath may consist of polymeric materials including but not limited tofilms, mesh screens, non-woven substrates, and rigid polymericstructures. In further embodiments, the sheath may consist of metalsurfaces including but not limited to metal foils, mesh screens, solidmetal sheets, and polymers with metalized surfaces.

FIG. 3 shows an exemplary embodiment of a panel manufacturing system 50used to manufacture insulation panels 10. Panel manufacturing system 50may include a feeding section having a hopper assembly 100, a rollerassembly 200, a fluid discharge system 300, and a feeding conveyor 500,a compression section having a compression conveyor 600, and a dischargesection having a creasing system 700 and a cutting system 800. Panelmanufacturing system 50 may be operatively supported by supportstructure 400, with a feeding section structure 410 supporting thefeeding section, a compression section structure 420 supporting thecompression section, and a discharge section structure 430 supportingthe discharge section.

Within the feeding section, discharge assembly (e.g., hopper assembly100) is configured to dispense foamed particulates 42 received from aparticulate feeder 900, and roller assembly 200 is configured todispense material for top and bottom barriers 20, 30 used to createinsulation panel 10, as shown in FIG. 4. Particulate feeder 900 mayinclude one or more extruders, a bulk particulate feeding system (e.g.,as shown in FIGS. 8A-E), or any suitable source of particulates 42.Fluid discharge system provides fluid to, in combination withcompression from compression conveyor 600, facilitate foamedparticulates 42 adhering to one another and to top and bottom barriers20, 30. Feeding conveyor 500 is configured to receive and direct barriermaterial for bottom barrier 30 and foamed particulates 42 to compressionconveyor 600, which also receives barrier material for top barrier 20from roller assembly 200. In turn, compression conveyor 600 compressesfoamed particulates 42 and the barrier materials together, and directsthe compressed materials to creasing system 700 and cutting system 800for creasing and cutting the compressed materials into individualinsulation panels 10. Panel manufacturing system 50 may optionally havea reclamation system 1000 for reclaiming scrap materials from thefeeding section and/or the creasing and cutting section that wouldotherwise be discarded and sending the scrap materials to particulatefeeder 900 or directly to hopper assembly 100.

FIG. 5 shows the exemplary embodiment of the feeding section of panelmanufacturing system 50 from FIGS. 3-4 in greater detail. Supported byfeeding section structure 410, hopper assembly 100 includes a firsthopper 110 positioned above an upstream portion of feeding conveyor 500and a second hopper 120 positioned above a middle portion of feedingconveyor 500. Both first hopper 100 and second hopper 120 contain foamedparticulate 42, which may be supplied by a particulate source, such asparticulate feeder 900 as shown in FIG. 4. Although hopper assembly 100is described herein as having two hoppers 110, 120, in some embodimentsa hopper assembly 100 may include only a single hopper, or,alternatively may have more than two hoppers. Returning to theembodiment shown in FIG. 4, first hopper 110 and second hopper 120dispense foamed particulates 42 via an outlet 114 onto a firstdistribution conveyor 112 and via an outlet 124 onto a seconddistribution conveyor 122, respectively, for subsequent distributiononto bottom barrier 30 below. First distribution conveyor 112 and seconddistribution conveyor 114 are configured to release foamed particulates42 into a respective discharge chute that is configured to guide foamedparticulates 42 down to bottom barrier 30 to prevent foamed particulates42 from bouncing upon contact. First hopper 110 and second hopper 120may each include one or more vibrating dampers 116, 126 configured tocause first and second hoppers 110, 120, respectively, to vibrate at oneof more predetermined frequencies or with variable frequency to, incombination with the rotation speed of first and second distributionconveyors 112, 122, control the discharge rate of foamed particulate2 42through outlets 114, 124. First hopper 110 and second hopper 120 mayalso include internal baffles that are moveable or removable toselectively prevent or substantially limit foamed particulate 42 fromdischarging onto particular regions of first distribution conveyor 112and second distribution conveyor 114, respectively. For example, whenpanel manufacturing system 50 is manufacturing insulation panels 10having a width less than the full width of feeding conveyor 500, theinternal baffles may direct the flow of foamed particulates 42 entirelyor substantially to a portion of outlets 114, 124 that correspond to adesired width of insulation panels 10. In some embodiments, first hopper110 and/or second hopper 120 may have an internal volume ofapproximately 130 cubic feet. First hopper 110 and/or second hopper 120may be constructed of stainless steel or corrosion-resistant steel. Thehoppers 110, 120 may have a trapezoidal or triangular shape tofacilitate the downward flow of foamed particulates 42 and may utilizevibration (e.g., via vibrating dampers 116, 126) to assist in thegravity-fed downward flow of foamed particulates 42. Particle flow canbe controlled by vibration frequency (e.g., air pressure), by the speedof the distribution conveyors 112, 122 conveyors, or by a combinationthereof. First hopper 110 and second hopper 120 may be mechanicallyadjustable in height from 0″ to 12″.

Also supported by feeding section structure 410, roller assembly 200includes one or more spare barrier rolls 210, a top barrier roller 220for dispensing material for top barrier 20, and a bottom barrier roller230 for dispensing material for bottom barrier 230. Spare barrierroll(s) 210 may be used to replace rolls of barrier material used on topbarrier roller 220 or bottom barrier roller 230. Top barrier roller 220and/or bottom barrier roller 230 may include an optical eye that iscapable of detecting the diameter of a roll of material (e.g.,paper-based material such as kraft paper) that is on the roller. Topbarrier roller 220 may be positioned downstream of hopper assembly 100and at the same height or higher than an upper inner surface ofcompression conveyor 600 to keep top barrier material taught and abovefoamed particulates 42 as it exits the feeding section. Bottom barrierroller 230 may be positioned upstream and below of the discharge pointof first and second distribution conveyors 112, 122 of hopper assembly100 so the bottom barrier material receives foamed particulates 42 fromhopper assembly 100. Top and bottom barrier rollers 220, 230 may beconfigured to unroll the barrier materials at a controlled rotation ratein cooperation with the discharge rate of the foamed particulates 42from hopper assembly 100. For example, top and bottom barrier rollers220, 230 may be configured to rotate at one or more predeterminedrotational rates or at a variable rotation rate. Top and bottom barrierrollers 220, 230 may be configured to handle rolls of barrier materialcut to various widths, thereby minimizing the downstream cutting ofbarrier material and allowing for minimal material waste because thewidth of barrier material rolls used can be selected based on thedesired width of insulation panels 10 being manufactured. Top and bottombarrier rollers 220, 230 may also include a mechanical fastener, such asa cap, clip, or snap, that holds rolls of barrier material in placeduring use and is selectively removable to allow empty rolls to bereplaced.

Positioned between top and bottom barrier rollers 220, 230 and supportedby feeding section structure 410, fluid discharge system 300 includes abottom barrier fluid discharger 310 for discharging fluid onto bottombarrier material being unrolled by bottom barrier roller 230, a foamedparticulate fluid discharger 320 for discharging fluid onto foamedparticulate 42, and a top barrier fluid discharger 330 for dischargingfluid onto top barrier material being unrolled by top barrier roller220. Each fluid discharger 310, 320, 330 includes a fluid outlet 312,322, 332 for selectively discharging fluid onto the materials, as shownin FIG. 4. In some embodiments, fluid dischargers 310, 320, 330 areconfigured to discharge water or water mixed with a carbohydrate such asstarch (in liquid or vaporized form), though other fluids or mixingmaterials, such as organic compounds that do not impede repulpability orrecyclability are contemplated. Fluid dischargers 310, 320, 330 mayinclude a plurality of water nozzles, fluid nozzles, water atomizers, orrollers that disperse fluid droplets or vaporized fluid (e.g., byspraying via nozzles or atomizers or applying via rollers) across thelength of feeding conveyor 500. One or more fluid dischargers 310, 320,300 may have one or more spray valves, including an Everloy SK06 nozzle,an air atomized nozzle, a fine spray nozzle, a hollow cone nozzle, aflat fan nozzle, or a full cone nozzle. Fluid dischargers 310, 320, 330may be configured to discharge fluid in a variety of spray patterns, forexample, a conical pattern, a curtain pattern, or a thin, triangularspray such that the spray from adjacent nozzles abut one another withminimal overlap, as shown in FIG. 4. The fluid discharge rate at eachnozzle or for each discharger can be controlled and set at one or morepredetermined fixed discharge rates or set at a variable discharge rateby, for example, applying greater water pressure or air pressure withinfluid dischargers 310, 320, 330 or by at least partially closing anozzle (e.g., by rotatably screwing it in to limit the size of its fluiddischarge opening). A typical air pressure used by the system is between5-100 PSI and a typical water pressure is between 5-100 PSI. The rate offluid discharged from a fluid discharger 310, 320, 330 can beselectively changed by adjusting the air pressure and/or water pressureon a water nozzle, fluid nozzle or water atomizer of a fluid discharger310, 320, 330.

Positioned below hopper assembly 100, roller assembly 200, and fluiddischarge system 300 and supported by feeding section structure 410,feeding conveyor 500 may include a conveyor belt 510 rotatably supportedby one or more conveyor rollers 520. Conveyor belt 510 may include afluid-resistant material or coating to help prevent the fluid from fluiddischarge system from damaging internal components of feeding conveyor500. Conveyor rollers 520 may be conventional conveyor rollers orvibrating conveyor rollers that cause vibration of conveyor belt 510 tohelp evenly distribute foamed particulate 42 over the bottom barriermaterial. In some embodiments, the entire assembly of feeding conveyor500 may be configured to vibrate.

Supporting various components of panel manufacturing system 50, supportstructure 400 may include multiple modular connected A-frame or U-framestructures made from, for example, corrosion-resistant steel. Themodular connected structures are designed to be easily added or removed.As shown in FIGS. 3-7, feeding section structure 410, compressionsection structure 420, and discharge section structure 430 may each formrectangular skeletal structures aligned in series. In some embodiments,support structure 400 has one or more “open” sides to allow for easy andconvenient access of materials and viewing of the manufacturing process.In other embodiments, support structure 400 has one or more “closed”sides, which may be selectively movable or removable, to containmaterials within panel manufacturing system 50 and protect operators andnearby equipment and materials.

Collectively, the feeding section is configured to dispense thematerials needed to construct insulation panel 10 in the properarrangement and panel width along with the fluid that helps thematerials to adhere together. As shown in FIG. 4, when in use, the topsurface of feeding conveyor 500 moves in a forward direction pullingbottom barrier material downstream away from bottom barrier roller 230.Bottom barrier fluid discharger 310 discharges a fluid spray 314 ontothe top surface of material forming bottom barrier 30 as bottom barrier30 is pulled onto feeding conveyor 500. Foamed particulates 42 are thendistributed onto the top surface of bottom barrier 30 by firstdistribution conveyor 112, creating a first layer of foamed particulate42. A bottom portion of this first layer of foamed particulates 42 atleast partially adheres to the top surface of bottom barrier 30 due tothe fluid previously applied by bottom barrier fluid discharger 310.

Next, as shown more clearly in FIG. 5 since the view is obstructed inFIG. 4, foamed particulate fluid discharger 320 discharges a fluid spray324 onto the top of the first layer of foamed particulates 42 before asecond layer of foamed particulate 42 is distributed on top of the firstlayer of foamed particulates 42 by second distribution conveyor 122. Insome embodiments, feeding conveyor 500 may optionally vibrate to causeloose foamed particulate 42 to shuffle around until it adheres to otherfoamed particulate 42 or to bottom barrier 30. A bottom portion of thesecond layer of foamed particulates 42 at least partially adheres to thefirst layer of foamed particulate due to the fluid applied by foamedparticulate fluid discharger 320.

As the second layer of foamed particulates 42 approaches the compressionconveyor 600, top barrier roller 220 positions the material forming topbarrier 20 onto the top surface of the second layer of foamedparticulates 42. The bottom surface of material forming top barrier 20is sprayed with fluid spray 334 from top barrier fluid discharger 330after it is drawn from top barrier roller 220 and before it is appliedto the second layer of foamed particulates 42. A bottom surface of topbarrier 20 at least partially adheres to the second layer of particulate42 due to the fluid applied by top barrier fluid discharger 330. In thisway, the feeding section creates a foamed particulate layer 40 that atleast partially adheres to itself and to top barrier 20 and bottombarrier 30 before being fed into compression conveyor 600 forcompression to the final height and to full adhere the materials. Inconjunction with compression, the fluid on the hydrated foamedparticulates 42 may help facilitate the mechanical and/or chemicaladhesion between foamed particulates 42 and between foamed particulatelayer 40 and top and bottom barriers 20, 30.

As shown in FIGS. 6A-B, the compression section is supported bycompression section structure 420 and includes compression conveyor 600,which is divided into a first compression section 610 and a secondcompression section 620. Compression conveyor 600 may include upper andlower conveyors 600U, 600L, respectively, which may form single,continuous conveyors (e.g., a set of compression rollers in someembodiments, and rollers combined with a conveyor belt in otherembodiments) that extend the entire length of compression conveyor 600or multiple conveyors that extend the length of the first and secondcompression sections 610, 620. Either way, upper and lower conveyors600U, 600L operate in unison to direct the material for the insulationpanel 10 generated by feeding section (as described above) into a feedend of first compressor section 610 towards a discharge end of secondcompressor section 620. The feed end of first compressor section 610 hasan inlet formed by the space between upper and lower conveyors 600U,600L, and the inlet has an inlet height 612. Moving downstream away fromthe inlet, the height of the space between upper and lower conveyors600U, 600L is gradually reduced from inlet height 612 to a compressionheight 622 at the end of first compressor section 610, and thecompression height 622 is maintained through the end of secondcompression section 620. In some embodiments, compression conveyor 600has an inlet height 612 up to about 12″ and a compression height betweenabout 0.125″ and 12″. The height of upper and lower conveyors 600U, 600Lmay be selectively adjustable such that the inlet height 612 andcompression height 622 are adjustable based on the desired final heightof insulation panel 10. In some embodiments, the inlet height 612 andcompression height 622 may be the same.

In operation, as shown in FIG. 4, top barrier 20, foamed particulates42, and bottom barrier 30 may have an uncompressed height that is lessthan or equal to the inlet height 612 and gradually compress as thematerial moves downstream within first compression section 610 untilultimately compressing to compression height 622. Then, compression ismaintained throughout the length of second compression section 620 tofacilitate full adherence between foamed particulates 42 to form foamedparticulate layer 40 and between foamed particulate layer 40 and top andbottom barriers 20, 30. This extended compression also fixes the heightof insulation panel 10, minimizing the extent that foamed particulatelayer 40 expands after exiting compression conveyor 600 and keeping theheight of insulation panel 40 uniform in advance of being cut orcreased. To ensure sufficient adhesion between foamed particulates 42and to prevent re-expansion of the insulation materials after exitingcompression conveyor 600, a minimum compressive force is required toadequately crush foamed particulate layer 40. The compression forcerequired to compress 1.0″ of wet foamed particulates 42 is about 20 to200 pounds per square foot in some embodiments, and about 50 to 150pounds per square foot in other embodiments. The application of aminimum compressive force to foamed particulate layer 40 paired with thebonding provided by the fluid applied to the foamed particulates 42facilitates adhesion between each of foamed particulates 42 and betweenfoamed particulate layer 40, top barrier 20, and bottom barrier 30. Inother embodiments, it is contemplated that second compression section620 may be angled as well.

To adjust inlet height 612 and the compression height 622 of compressionconveyor 600, compression conveyor 600 includes a front actuator 632, amiddle actuator 634, and a rear actuator 636. For example, frontactuator 632 vertically adjusts the inlet end of upper conveyor 600U toadjust inlet height 612, middle actuator 634 vertically adjusts themiddle portion of upper conveyor 600U to adjust compression height 622,and rear actuator vertically adjust the outlet end of upper conveyor600U. In other embodiments, the height of various portions of upperconveyor 600U and/or lower conveyor 600L may be manually adjustable byan operator or by a mechanical or electrical adjustment system, as willbe appreciated by one of skill in the art. Accordingly, compressionconveyor 600 is capable of outputting insulation panel materials ofhaving different thicknesses, enabling panel manufacturing system 50 tomanufacture insulation panels 10 of various uniform heights.

Optionally, compression conveyor 600 may include or be in communicationwith one or more heat sources (not shown), and configured to transferheat to insulation panel materials to further facilitate adherence ofthe insulation panel materials during compression. A person of skill inthe art would appreciate that heated compression is more effective andlasting (e.g., helps prevent expansion following compression) forcertain materials by accelerating the binding of foamed particulates 42to each other and top and bottom barriers 20, 30.

As shown in FIGS. 7A-B, creasing and cutting section is supported bydischarge section structure 430 and includes creasing system 700 forcreasing the edges of top barrier 20 and bottom barrier 30 around foamedparticulate layer 40 and cutting system 800 for cutting the insulationmaterials into unitary insulation panels 10 of a desired length (and, asneeded, width). FIG. 7A shows one exemplary embodiment of creasing andcutting section, in which creasing system 700 includes a creasing rollerassembly 710 and cutting system 800 includes a cutting rolling assembly810, a longitudinal cutting blade assembly 820, and a lateral cuttingblade assembly 830. Creasing roller assembly 710 creases perpendicularto feed direction, and operates at pre-timed intervals. When creasingroller assembly 710 rotates downwardly towards incoming panel materials,it hits the panel. When creasing roller assembly 710 rotates upwardlytowards incoming panel materials, the panel materials pass belowcreasing roller assembly 710 untouched. Optionally, in some embodimentsas shown in FIG. 7B, creasing system 700 includes a creasing bladeassembly 720, which has one or more blades configured to partiallydeform one or more edges of insulation panel 10 that parallel the feeddirection to crease the side edges of top barrier 20 and bottom barrier30 around foamed particulate layer 40 in addition to or in lieu ofcreasing roller assembly 710. According to some embodiments, creasingblade assembly 720 can be used instead of creasing roller assembly 710when the incoming panel materials enter creasing system 700perpendicularly to the machine direction in order to perform thecreasing “in-line” rather than perpendicular to the machine direction.In some embodiments, creasing system 700 may utilize two dull-bladesthat allow insulation panel 10 to fold at a 90 degree angle withouttearing or damaging top or bottom barriers 20, 30. Creasing system 700is servo driven, enabling accurate positioning of the insulationmaterials for creasing. After exiting creasing system 700, eachinsulation panel 10 will have two creases.

After insulation panel 10 has been creased, nip roller assembly 810stabilizes insulation panel 10 for cutting blade assemblies 820, 830.Nip roller assembly 810 may include upper and lower rollers or sets ofrollers, as shown, and may be positioned between longitudinal cuttingblade assembly 820 and lateral cutting blade assembly 830 (FIG. 7A) orupstream and downstream of lateral cutting blade assembly 820 (FIG. 7B).Longitudinal cutting blade assembly 820 includes one or more bladesconfigured to cut insulation materials into unitary insulation panels ofa desired width. Lateral cutting blade assembly 830 includes one or moreblades (e.g., a guillotine style blade extending at least the fulllength of each insulation panel 10) configured to cut insulationmaterials into unitary insulation panels of a desired length. It iscontemplated that cutting system 800 may include either or both cuttingassemblies 820, 830, and some cutting or trimming of insulation panels10 may be handled by equipment outside of panel manufacturing system 50(e.g., handled by on-site equipment if exact dimensions for insulationpanel 10 are not known in advance).

In some embodiments, as shown in FIGS. 8A-8E, a panel manufacturingsystem 50 includes a bulk particulate feeding system 902 as an exemplarytype of particulate feeder 900 and a reclamation system 1002 as anexemplary type of reclamation system 1000. Bulk particulate feedingsystem 902 has one or more bulk feeding hoppers 910A, 910B, 910C, and910D containing foamed particulates 42 that are fed into first hopper110 and second hopper 120 via a bulk feeding conveyor 920 and a deliveryconveyor system 930. Specifically, bulk feeding hoppers 910A, 910B,910C, 910D dispense foamed particulates 42 onto a conveyor belt 922,which elevates the foamed particulates 42 so that they may be dispensedonto delivery conveyor 930. Conveyor belt 922 has a plurality of ridges924 that prevent foamed particulate 42 from rolling backwards asconveyor belt 922 inclines and declines, which eliminates the additionalspace required to suspend bulk feedings hoppers 910A, 910B, 910C, 910Dabove delivery conveyor system 930 and panel manufacturing system 50.

When foamed particulates 42 reach the end of conveyor belt 922, a firstportion of foamed particulates 42 is dropped onto a first deliveryconveyor 932 of delivery conveyor system 930 that delivers the firstportion of foamed particulates 42 to first hopper 110, and a secondportion of foamed particulates 42 is dropped onto a second deliveryconveyor 934 of delivery conveyor system 930 that delivers the secondportion of foamed particulates 42 to second hopper 120, as shown inFIGS. 8A-8E. Bulk feeding hoppers 910A, 910B, 910C, 910D can havecontrollably moveable internal baffles that enable foamed particulates42 to be selectively dispensed onto different regions of the surface ofconveyor belt 922 (e.g., direct all foamed particulates onto a left halfof conveyor belt 922 if only delivery conveyor 932 and first hopper 110are in operation for a particular job in the same manner described abovewith respect to the baffles of hoppers 110 and 120). Accordingly, asshown in FIG. 8C, conveyor belt 922 may unevenly distribute foamedparticulate 42 to first delivery conveyor 932 and second deliveryconveyer 934 by virtue of an uneven distribution of foamed particulate42 on the surface of conveyor belt 922 caused by the use of the baffles.

Reclamation system 1002 reclaims scrap materials from the feedingsection and/or the creasing and cutting section that would otherwise bediscarded and sends the scrap materials to particulate feeding system902. Reclamation system 1002 may include a hammermill 1010 for crushingthe scrap materials, a main vacuum 1020 for suctioning the scrapmaterials into hammermill 1010, a plurality of reclamation pipesincluding a main pipe 1030 having an upstream joint 1050 with upstreampipes 1040 extending downwards towards the feeding section and adownstream joint 1060 with downstream pipes 1070, and a discharge pipe1090. Hammermill 1010 may internally include one or more mesh screenshaving a plurality of openings sized to filter particulates of differentsizes and shapes, thereby preventing oversized particulates from passingthrough hammermill 1010 and directed back into panel manufacturingsystem 50 (e.g., via one or more hoppers). The particulates will begrinded or shredded down until they reach the threshold maximum size andshape necessary to pass through an opening in at least one of the meshscreens, at which point the particulate may pass through the hammermill.Discharge pipe 1090 may be configured to direct (e.g., via main vacuum1020 or one or more blowers or vibrating dampers disposed within or influid communication with discharge pipe 1090) crushed scrap materialsfrom hammermill 1010 back into one or more of hoppers 110, 120, 910A,910B, 910C, and 910D.

The reclamation pipes may be sized and shaped to transport scrapmaterial of a variety of sizes and shapes. It is contemplated that thereclamation pipes may be flexible to accommodate scrap materials ofvarious sizes and shapes. Main pipe 1030 may be between 3 inches and 24inches in diameter, and is in fluid communication with upstream pipes1040 through upstream joint 1050 and with downstream pipes 1070 throughdownstream joint 1060. Upstream pipes 1040 may be between about 3 inchesto 24 inches in diameter, and downstream pipes may also be between about3 inches to 24 inches in diameter. Upstream and downstream joints 1050,1060 may be between about 3 to 24 inches in diameter.

Shown more clearly in FIG. 8D, upstream pipes 1040 may be positionedproximate second hopper 120 and feeding conveyor 500, and each pipe 1040includes a vacuum strip 1042 for suctioning scrap material proximate theedges of feeding conveyor 500. Optionally, upstream pipes 1040 mayalternatively or additionally extend downwardly proximate first hopper110, or extend the entire length of feeding conveyor 500. The number andsize of upstream pipes 1040 may vary based on the size and strength ofvacuum stripes 1042 and anticipated volume of scrap material.

Shown more clearly in FIG. 8E, downstream pipes 1070 may be positionedimmediately downstream of cutter system 800, and each pipe 1070 mayinclude a grinder 1080 for grinding freshly cut scrap material proximatecutting system 800 to resize and reshape all scrap materials enteringdownstream pipes 1070 via inlet chutes 1082 to fit within reclamationsystem 1002. Grinder 1080 may include one or more trim “choppers” thatare vacuum assisted. The waste trim enters the choppers and is grindedinto a coarse particle size and transported to hammermill 1010 using avacuum.

FIG. 9 shows an exemplary embodiment of panel manufacturing system 50having a controller 950. Controller 950 can be a variety of electronicdevices programmable to control the various functions of the panelmanufacturing system 50, such as the hopper assembly 100, rollerassembly 200, fluid discharge system 300, feeding conveyor 500,compression conveyor 600, creasing system 700, cutting system 800,particulate feeder 900, and reclamation system 1000. Controller 950 canbe a microcontroller that is, for example, programmable orpre-programmed (e.g., application specific integrated circuits (ASICs)).Alternatively, controller 950 can be a PC, server, mainframe, or othercomputer programmed device that controls aspects of panel manufacturingsystem 50. Controller 950 can include an application (or, “app”) on asmartphone or tablet. Controller 950 can be connected to the systemusing, for example, a direct wired connection, an Ethernet connection(e.g., Ethernet PLC communication for plant data interface), a localarea network (LAN), a wireless local area network (WLAN), an internetconnection, a wireless connection, Bluetooth, near-field communication(NFC), or a cellular or radio connection. Controller 950 can also benetworked via a similar connection to enable remote operation andcontrol.

Controller 950 can control various aspects of panel manufacturing system50 to achieve an efficient and orderly production of insulation panels50 by adjusting various aspects so that the process flow is balanced andavoids bottlenecks and other such issues. For example, with respect tohopper assembly 100 and similarly with respect to bulk particulatefeeding system 902, controller 950 can control the frequency of hoppervibration and the rotation speed of first and second distributionconveyors 112, 122 in order to affect the discharge rate of foamedparticulate 42 out of outlets 114, 124 of hoppers 110, 120 (andsimilarly for hoppers 910 a, 910 b, 910 c, 910 d and conveyors 920, 930in bulk feeding system 902). In some embodiments, controller 950 may bein communication with one or more sensors (not shown) disposed betweenhoppers 110, 120 that are configured to detect the height of foamedparticulate 42. When controller 950 determines that the detected heightof foamed particulate 42 exceeds a predetermined threshold (e.g., aboveor below a target height), controller 950 may direct the rotation speedof the first and second distribution conveyors to increase or decreaseto adjust the height of the foamed particulate 42 within the thresholdrange of the target height. Controller 950 may also control the internalbaffles of hoppers 110, 120, 910A, 910B, 910C, 910D to control thedistribution of foamed particulate 42 that is dispensed on the surfacebelow (e.g., onto a portion of a conveyor). Thus, controller 950 cancontrol the rate and distribution at which the hoppers 110, 120, 910 a,910 b, 910 c, 910 d dispense foamed particulate onto distributionconveyors 112, 114 and/or bulk feeding conveyor 920. Further, controller950 can independently control the speed of each conveyor 500, 600, 112,114, 922, 932, 934 of panel manufacturing system 50, thereby enablingcontrol of the amount and the speed of foamed particulate 42 at variouspoints in panel manufacturing system 50. Thus, for example, if there aretoo many foamed particulates 42 in first hopper 110 such that it is atrisk of overflowing, controller 950 may take one or more actions toavoid an overflow, such as reducing the speed of first delivery conveyor932 and/or conveyor belt 922, reducing the speed that bulk particulatefeeding system dispenses foamed particulate 42 onto conveyor belt 922,adjusting one or more baffles of bulk feeding hoppers 910A, 910B, 910C,910D to reduce the quantity of foamed particulate directed at firstdelivery conveyor 932, or increasing the speed first hopper 110dispenses foamed particulate onto feeding conveyor 500 (as describedabove). In addition to controlling the speed of feeding conveyor 500, insome embodiments, controller 950 is also configured to activate andcontrol the vibration of feeding conveyor 500.

With respect to roller assembly 200, controller 950 is configured tocontrol the speed of top barrier roller 220 and bottom barrier roller230 to align with the speed of feeding conveyor 500 and compressorconveyer 600 such that top barrier 20 and bottom barrier 30 areuniformly dispensed on the conveyors 500, 600. Further, controller 950may receive a signal from one or more optical eyes positioned about topbarrier roller 220 and/or bottom barrier roller 230 that indicates thediameter of the roll that remains on a roller. When a roll (e.g., ofkraft paper) reaches a predetermined minimum diameter, controller 950may send a signal to cause one or more aspects of panel manufacturingsystem 50 (e.g., fluid discharge system 300, feeding conveyor 500,compressor conveyor 600) to temporarily cease operation to prevent wastewhile the roll is replaced.

With respect to fluid discharge system 300, controller 950 is configuredto selectively control the air pressure and/or water pressure of one ormore fluid dischargers 310, 320, 330 to control the rate at which fluidis dispensed. Controller 950 may also be configured to selectively closeor partially close one or more nozzles of fluid dischargers 310, 320,330 to affect the fluid discharge area, flow rate, or spray shape. Forexample, controller 950 may selectively close the right-most two nozzlesof fluid dischargers 310, 320, 330 to prevent fluid from dischargingdirectly onto feeding conveyor 500 if the top and bottom barriermaterials have a smaller width and foamed particulates 42 are beingrestricted from flowing onto the right side of feeding conveyor 500.

With respect to compression conveyor 600, controller 950 is configuredto control the height adjustments of upper conveyor 600U relative tolower conveyor 600L as well as the timing sequence of conveyors 600U and600L to uniformly pull top barrier 20 and bottom barrier 30 withincompression conveyor 600. Additionally, controller 950 may be configuredto control operation of heat sources in fluid communication withcompression conveyor, thereby controller temperature and exposureduration for heating during the compression phase of manufacturing.

With respect to creasing system 700 and cutting system 800, controller950 is configured to control the timing sequence of creasing cutterassembly 720 and cutting cutter assembly to yield cut and creasedinsulation panels 50 of a predetermined size and geometry. Controller950 can also be in communication with one or more sensors (not shown)disposed in panel manufacturing system 50 and adjust settings of varioussystems to provide quality control. For example, when controller 950 hasspecified a predetermined height, length, and width for insulation panel10, sensors may measure the various dimensions of insulation panel 10following cutting or following each respective stage in themanufacturing process. Controller 950 may determine that, based onmeasurement data from the sensors, settings adjustments are required forone or more systems within panel manufacturing system 50 (e.g., measuredheight does not equal predetermined height due to expansion of materialsafter exiting compression conveyor 600), and communicate the adjustmentsto those systems (e.g., adjust heights of compression conveyor 600 toaccount for expansion so insulation panel 10 has predetermined height).

With respect to reclamation system 1000, controller 950 is configured tocontrol which pipes (upstream and downstream) are active, the speed ofvacuum(s), and the settings of material crushing and grinding devices toensure that reclamation system 1000 functions as desired. Controller 950may also estimate levels of foamed particulate 42 needed to complete aparticulate job, track how much scrap material has been collected byreclamation system 1000, and limit or shut off operation of particulatefeeder 900 when controller 950 determines that collected scrap materialis sufficient to complete the job without or with minimal additionalfoamed particulate 42 from particulate feeder 900.

FIG. 10 is a flowchart of a method 1100 for fabricating an insulationpanel 10, in accordance with an exemplary embodiment. At block 1110, themethod includes directing a first fluid (e.g., water or water mixed witha carbohydrate such as starch, in either liquid or vaporized form) ontoan upper surface of a bottom barrier 30. For example, bottom barrierfluid discharger 310 may direct a first fluid onto bottom barrier 30that is dispensed onto feeding conveyor 500 from bottom barrier roller230.

At block 1120, method 1100 includes distributing a plurality ofparticulates about the upper surface of the bottom barrier 30. Theparticulates may be puffed carbohydrate (e.g., polysaccharides such asstarch, including vegetable starch, or cellulose) particles, or acombination thereof. For example, particulates originating fromdischarge assembly (e.g., first hopper 110 and/or second hopper 120) maybe dropped onto the upper surface of bottom barrier 30 by firstdistribution conveyor 112 and/or second distribution conveyor 114. Insome embodiments, distributing the plurality of particulates (e.g.,foamed particulates 42) about the upper surface of the bottom barrier 30may include providing a first layer comprising primary particulates ontothe upper surface of the bottom barrier 30 and providing a second layercomprising secondary particulates onto the first layer. In someembodiments, the secondary particulates differ from the primaryparticulates (e.g., in size, shape, and/or composition). It is alsocontemplated that the primary and secondary particulates may come fromdifferent sources (e.g., from an extruder and from shredded scrapmaterial recovered by reclamation system 1000). In other embodiments,distributing the plurality of particulates (e.g., foamed particulates42) about the upper surface of the bottom barrier may includingvibrating at least a portion of the bottom barrier to distribute theplurality of particulates into a substantially uniform particulate layeralong the portion of the bottom barrier.

At block 1130, method 1100 involves directing a second fluid (e.g.,water or water mixed with a carbohydrate such as starch, in eitherliquid or vaporized form) onto at least a portion of the plurality ofparticulates. For example, foamed particulate fluid discharger 320 maydirect a second fluid onto a portion of the plurality of particulatesthat are positioned on top of bottom barrier 30 as it proceeds downfeeding conveyor 500. In some embodiments, directing a second fluidcomprises applying the second fluid between a first layer ofparticulates and a second layer of particulates. According to someembodiments where a thinner insulation panel 10 and/or a thinner foamedparticulate layer 40 is desired, method 1100 may omit step 1130.

At block 1140, method 1100 involves directing a third fluid (e.g., wateror water mixed with a carbohydrate such as starch, in either liquid orvaporized form) onto at least a lower surface of a top barrier 20. Forexample, top barrier fluid discharger 330 may direct a third fluid ontoa lower surface of top barrier 20 as top barrier is pulled from topbarrier roller 220. According to some embodiments, the first, second,and third fluids are vaporized water.

At block 1150, method 1100 involves positioning the top barrier 20 ontop of the plurality of particulates such that the plurality ofparticulates forms an insulation section (e.g., foamed particulate layer40) disposed between the top barrier 20 and the bottom barrier 30. Forexample, top barrier 20 may pulled off of top barrier roller 220 andplaced on top of the plurality of particulates as the plurality ofparticulates advances down feeding conveyor 500. Top and bottom barriers20, 30 may be paper-based barriers.

At block 1160, method 1100 involves compressing the insulation sectionand the top and bottom barriers 20, 30 such that at least a portion ofthe insulation section at least partially adheres to the top and bottombarriers 20, 30 to form an insulation panel 10. For example, compressionconveyor 600 may compress the insulation section, as shown in FIG. 4. Insome embodiments, compressing the insulation section and the top andbottom barriers 20, 30 includes compressing the insulation section andthe top and bottom barriers 20, 30 to a first height in a first sectionof a compression conveyor 600, and compressing the insulation sectionand the top and bottom barriers 20, 30 to a second height in a secondsection of the compression conveyor 600, where the first height differsfrom the second height, and the first and second height are adjustable.At least a portion of the discrete particulates of the insulation may atleast partially chemically adhere to one another and to the top andbottom barriers 20, 30 by, for example, covalent bonds, ionic bonds,hydrogen bonds, or any combination thereof as described herein. Forexample, the particulates of the insulation core layer may at leastpartially adhere to one another and/or to the top and/or bottom barriersvia direct chemical adhesion or adhesive layer. The direct chemicaladhesion can be via a covalent bond, including, but not limited to, aglycosidic linkage (e.g., an “O”-glycosidic linkage).

In some embodiments, method 1100 may further include heating theinsulation panel 10 to at least partially and/or further adhere to theplurality of particulates to one another and to the top and bottombarriers 20, 30. The method may further include cutting the heatedinsulation panel 10 into a plurality of polygonal sheets. Method 1100may also include vibrating at least a portion of the bottom barrier todistribute the plurality of particulates into a single layer along theportion of the bottom barrier.

The design and functionality described in this application is intendedto be exemplary in nature and is not intended to limit the instantdisclosure in any way. Those having ordinary skill in the art willappreciate that the teachings of the disclosure may be implemented in avariety of suitable forms, including those forms disclosed herein andadditional forms known to those having ordinary skill in the art. Thisdisclosure is intended to cover various modifications and equivalentarrangements included within the scope of the appended claims. Althoughspecific terms are employed herein, they are used in a generic anddescriptive sense only and not for purposes of limitation.

It must also be noted that, as used in the specification and theappended claims, the singular forms “a,” “an” and “the” include pluralreferents unless the context clearly dictates otherwise.

By “comprising” or “containing” or “including” is meant that at leastthe named compound, element, particle, or method step is present in thecomposition or article or method, but does not exclude the presence ofother compounds, materials, particles, method steps, even if the othersuch compounds, material, particles, method steps have the same functionas what is named.

It is also to be understood that the mention of one or more method stepsdoes not preclude the presence of additional method steps or interveningmethod steps between those steps expressly identified. Similarly, it isalso to be understood that the mention of one or more components in adevice or system does not preclude the presence of additional componentsor intervening components between those components expressly identified.

As used herein, unless otherwise specified the use of the ordinaladjectives “first,” “second,” “third,” etc., to describe a commonobject, merely indicate that different instances of like objects arebeing referred to, and are not intended to imply that the objects sodescribed must be in a given sequence, either temporally, spatially, inranking, or in any other manner.

As used herein, “bending” may refer to the ability of containerboard orcombined board to be folded along scorelines without rupture of thesurface fibers to the point of seriously weakening the structure.

As used herein, “biodegradable” may refer to a substance that isdegradable over time by water and/or enzymes found in nature (e.g.,compost), without harming, and in fact helping, the environment.

As used herein, “compostable” may refer to a product that will compostin such a manner that it is eligible for certification through theVincott “OK Compost” labelling program.

As used herein, “compression strength” may refer to a corrugated box'sresistance to uniformly applied external forces. Top-to-bottomcompression strength is related to the load a container may encounterwhen stacked. End-to-end or side-to-side compression may also be ofinterest for particular applications.

As used herein, “corrugator” may refer to the machine that unwinds twoor more continuous sheets of containerboard from rolls, presses flutesinto the sheet(s) of corrugating medium, applies adhesive to the tips ofthe flutes and affixes the sheet(s) of linerboard to form corrugatedboard. The continuous sheet of board may be slit to desired widths, cutoff to desired lengths and scored in one direction.

As used herein, “degradable” may refer to a substance that will undergoa process of deterioration or breaking-up by the action of naturalforces (air, light, water) or by the addition of certain chemicals.

As used herein, “dimension” may refer to, for a regular slottedcontainers (RSC), box dimensions are expressed as length×width×height,always using inside dimensions.

As used herein, “facings” may refer to sheets of linerboard used as theflat outer members of combined corrugated board. Sometimes called insideand outside liners.

As used herein, “fiberboard” may refer to combined paperboard(corrugated or solid) used to manufacture containers.

As used herein, “flaps” may refer to an extension of the side wallpanels that, when sealed, close the remaining openings of a box. Usuallydefined by one scoreline and three edges.

As used herein, “kraft” may refer to a German word meaning “strength”;designating pulp, paper or paperboard produced from wood fibers.

As used herein, “linerboard” may refer to the flat sheets of paper thatcomprise the outer surfaces of a sheet of corrugated board.

As used herein, “medium” may refer to the paperboard used to make thefluted layer of corrugated board.

As used herein, “overlap” may refer to a design feature wherein the topand/or bottom flaps of a box do not butt, but extend one over the other.The amount of overlap is measured from flap edge to flap edge.

As used herein, “panel” may refer to a “face” or “side” of a box.

As used herein, “paperboard” may refer to one of the two major productcategories of the paper industry. Includes the broad classification ofmaterials made of cellulose fibers, primarily wood pulp and recycledpaper stock, on board machines.

As used herein, “recyclable” may refer to any product that is eligiblefor either curbside collection or for being accepted into recyclingprograms that use drop-off locations, particularly products grantedpermission to use the corrugated recycles symbol of the Fibre BoxAssociation (FBA) in accordance with its guidelines (see, e.g.,http://corrugated.org/upload/CPA/Documents/Vol_Std_Protocol_2013.pdf).

As used herein, “score” or “scoreline” may refer to an impression orcrease in a rigid surface or board, made to position and facilitatefolds.

As used herein, “score and slotted sheet” may refer to a sheet ofcorrugated fiberboard with one or more scorelines, slots or slits. Maybe further defined as a box blank, a box part, a tray or wrap, apartition piece, or an inner packing piece.

As used herein, “seam” may refer to the junction created by any freeedge of a container flap or panel where it abuts or rests on anotherportion of the container and to which it may be fastened by tape,stitches or adhesive in the process of closing the container.

As used herein, “slit” may refer to a cut made in a fiberboard sheetwithout removal of material.

As used herein, “slit score” may refer to shallow knife cuts made in abox blank to allow its flaps and sides to be folded into a shipping box.

As used herein, “slot” may refer to a wide cut, or pair of closelyspaced parallel cuts including removal of a narrow strip of materialmade in a fiberboard sheet, usually to form flaps and permit foldingwithout bulges caused by the thickness of the material.

This written description uses examples to disclose certain embodimentsof the technology and also to enable any person skilled in the art topractice certain embodiments of this technology, including making andusing any apparatuses or systems and performing any incorporatedmethods. The patentable scope of certain embodiments of the technologyis defined in the claims, and may include other examples that occur tothose skilled in the art. Such other examples are intended to be withinthe scope of the claims if they have structural elements that do notdiffer from the literal language of the claims, or if they includeequivalent structural elements with insubstantial differences from theliteral language of the claims.

We claim:
 1. An insulation panel comprising: an insulation core layercomprising a plurality of discrete puffed polysaccharide particulatescomprising at least a first particulate and a second particulate, thefirst particulate being at least partially adhered to at least thesecond particulate without the use of external adhesives, the pluralityof discrete particulates defining a plurality of voids within the corelayer.
 2. The insulation panel of claim 1, wherein the first particulateis at least partially mechanically adhered to at least the secondparticulate without the use of external adhesives and without theapplication of heat to the first particulate and the second particulate.3. The insulation panel of claim 1 further comprising an outer layerthat at least partially covers the insulation core layer.
 4. Theinsulation panel of claim 3, wherein the insulation core layer comprisesa plurality polygonal insulation sheet sub-layers each comprising aplurality of discrete puffed polysaccharide particulates, the outerlayer covering the plurality of insulation core sub-layers.
 5. Theinsulation panel of claim 1, wherein the first particulate is at leastpartially adhered to at least the second particulate through one or morepolymerization reactions between a polysaccharide component within thefirst particulate and a polysaccharide component within the secondparticulate.
 6. The insulation panel of claim 1, wherein the firstparticulate is at least partially adhered to at least the secondparticulate through one or more hydration-aided polymerization reactionsbetween a polysaccharide component within the first particulate and apolysaccharide component within the second particulate.
 7. Theinsulation panel of claim 1 further comprising: a top barrier at leastpartially covering a top surface of the insulation core layer, the topbarrier being at least partially adhered to a first portion of theplurality of discrete particulates; and a bottom barrier at leastpartially covering a bottom surface of the insulation core layer, thebottom barrier being at least partially adhered to a second portion ofthe plurality of discrete particulates.
 8. The insulation panel of claim7, wherein the top barrier is at least partially adhered to the firstportion of the plurality of discrete particulates without the use ofexternal adhesives, and the bottom barrier is at least partially adheredto the second portion of the plurality of discrete particulates withoutthe use of external adhesives.
 9. The insulation panel of claim 7,wherein the first particulate is at least partially chemically adheredto at least the second particulate via a first covalent bond and theinsulation core layer is at least partially chemically adhered to thetop barrier via a second covalent bond and the bottom barrier via athird covalent bond.
 10. The insulation panel of claim 9, wherein one ormore of the first, second, and third covalent bonds comprises an“O”-glycosidic linkage.
 11. The insulation panel of claim 10, whereinthe plurality of discrete particulates comprises one or more starchvegetable particulates.
 12. The insulation panel of claim 1, wherein thefirst particulate comprises a first previously-hydrated outer surfaceand a first non-hydrated outer surface, the first previously-hydratedouter surface forming a bond with at least a portion of the secondparticulate to at least partially adhere the first and secondparticulates.
 13. The insulation panel of claim 1, wherein one or moreof the plurality of voids are at least partially filled with one or moreof a cellulose filler, a shredded paper filler, and a recyclablereclaimed waste trim filler.
 14. The insulation panel of claim 1,wherein a majority of the plurality of discrete particulates eachcomprise a generally cylindrical segment, the majority of the pluralityof particulates each having a diameter between about 0.5″ to about 2.0″.15. The insulation panel of claim 1 further comprising at least twocreases separating at least three sections of the insulation panel, eachof the at least three sections of the insulation panel being foldablerelative to one another along one or more of the at least two creases.16. An insulation panel comprising: a top paper-based barrier comprisingkraft paper; a bottom paper-based barrier comprising kraft paper; and aninsulation core layer disposed between to the top and bottom barriers,at least a first portion of the core layer being at least partiallyadhered to the top barrier and at least a second portion of the corelayer being at least partially adhered to the bottom barrier, the corelayer comprising a plurality of discrete compressed puffedpolysaccharide particulates comprising at least a first particulate anda second particulate, the first particulate being at least partiallyadhered to at least the second particulate without using externaladhesives.
 17. The insulation panel of claim 16, wherein the firstparticulate is disposed proximate an upper surface of the core layer andhydrated with a first fluid, and the second particulate is disposedproximate a lower surface of the core layer and hydrated with a secondfluid.
 18. The insulation panel of claim 16, wherein the plurality ofdiscrete particulates defines a plurality of voids within the corelayer, and one or more of the plurality of voids are at least partiallyfilled with one or more of a cellulose filler, a shredded paper filler,and a recyclable reclaimed waste trim filler.
 19. The insulation panelof claim 16, wherein at least the first particulate of the plurality ofdiscrete particulates comprises a first previously-hydrated outersurface and a first non-hydrated outer surface, the firstpreviously-hydrated outer surface of the particulate forming a bond withat least a portion of the second particulate to at least partiallyadhered the first and second particulates.
 20. The insulation panel ofclaim 16 further comprising at least two creases separating at leastthree sections of the insulation panel, each of the at least threesections of the insulation panel being foldable relative to one anotheralong one or more of the at least two creases.
 21. An insulation panelcomprising: an insulation core layer comprising a plurality of discretepolysaccharide particulates comprising at least a first particulate anda second particulate, the first particulate being at least partiallyadhered to at least the second particulate without the use of externaladhesives and without the application of heat to the first particulateand the second particulate; and an outer layer that at least partiallycovers the insulation core layer, the outer layer being at leastpartially adhered to one or more of the first and second particulates ofthe core layer without using external adhesives.
 22. The insulationpanel of claim 21, wherein the plurality of discrete particulates hasbetween about 20% and about 85% by dry-basis weight starch and particledensities varying from about 0.4 to about 0.9 pounds per cubic foot. 23.The insulation panel of claim 21, wherein the core layer has a densityfrom about 0.01 to about 2.0 pounds per cubic foot and a thicknessbetween about 0.025 to about 2.0 inches and is formed with between about30% to about 60% voids.
 24. The insulation panel of claim 21, wherein atleast the first particulate of the plurality of discrete particulatescomprises a first previously-hydrated outer surface and a firstnon-hydrated outer surface, the first previously-hydrated outer surfaceof the particulate forming a bond with at least a portion of the secondparticulate to at least partially adhered the first and secondparticulates.
 25. The insulation panel of claim 21, wherein the firstand second particulates each have a cross-section that is circular tolenticular in shape.